Methods and systems for upgrading hydrocarbon

ABSTRACT

Methods and systems of upgrading hydrocarbon material, such as bituminous material, are described. The methods and systems can reduce or eliminate the need for the use of atmospheric and/or vacuum distillation towers by instead using clyconic separation apparatus. The methods and systems can include the use of one or more cyclonic separation apparatus aligned in series in order to separate out a high boiling point fraction of the hydrocarbon material and then upgrading the high boiling point hydrocarbon material in a nozzle reactor.

This application claims priority to U.S. Provisional Patent Application No. 61/547,507, filed Oct. 14, 2011, the entirety of which is hereby incorporated by reference.

BACKGROUND

Hydrocarbon extraction and upgrading processes, such as have been carried out on oil sands and bitumen, typically entail separation steps in order to isolate various components of the hydrocarbon material extracted from hydrocarbon deposits. For example, when oil sands are extracted from an oil sands deposit, the extracted material is typically subjected to various separation processes that separate the bitumen component of the oil sands from the sand, water, clay, and other solid deposits that can be found in oil sands. The separated bitumen can also be subjected to separation processing in order to separate light hydrocarbon fractions that may already be suitable for commercial uses, such as naphtha, from heavy hydrocarbon fractions that require upgrading before they can be commercially useful and/or readily transported through pipelines to upgrading facilities.

Traditional extraction and upgrading processes use distillation towers for the separation of light hydrocarbons from heavy hydrocarbons. In some processes, both atmospheric and vacuum distillation towers are used in order to separate bitumen material. For example, the bitumen can first be processed in an atmospheric distillation tower in order to separate naphtha and light gas oil from the bitumen, followed by treating the remaining bitumen in a vacuum distillation tower in order to separate vacuum gas oil from the bitumen. The remaining portion of the original bitumen stream will generally include the heaviest fraction of hydrocarbon material, and can be sent to an upgrader, such as a nozzle reactor, in order to upgrade the heavy hydrocarbon material into more commercially useful and transportable hydrocarbon material.

However, several problems are associated with the use of distillation towers for the separation of a hydrocarbon material into various streams. For example, distillation towers tend to be large structures having large footprints. This makes distillation towers difficult or impossible to incorporate in situations where space is limited, such as on offshore platforms. Additionally, distillation towers have relatively high capital, operating, and maintenance expenses, which can drive down the economics of extraction and upgrading processes using distillation towers for separation steps.

SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary, and the foregoing Background, is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.

In some embodiments, a hydrocarbon upgrading method is disclosed. The method includes providing a hydrocarbon material having light hydrocarbon molecules and heavy hydrocarbon molecules; separating the light hydrocarbon molecules of the hydrocarbon material from the heavy hydrocarbon molecules of the hydrocarbon molecules using a cyclonic separation; and upgrading the heavy hydrocarbon molecules in a nozzle reactor.

In some embodiments, a hydrocarbon upgrading method is disclosed. The method includes providing a hydrocarbon material; separating the hydrocarbon material into a first heavy stream and a first light stream in a first hydrocyclone; separating the first heavy stream into a second light stream and a second heavy stream in a second hydrocyclone; and upgrading the second heavy stream in a nozzle reactor.

In some embodiments, a hydrocarbon upgrading system is disclosed. The system includes a hydrocyclone having a light stream outlet and a heavy stream outlet, and a nozzle reactor. In some embodiments, the heavy stream outlet of the hydrocyclone is in fluid communication with the second material feed port of the nozzle reactor.

In some embodiments, a hydrocarbon upgrading system is disclosed. The system includes a first hydrocyclone having a first light stream outlet and a first heavy stream outlet; a second hydrocyclone having a first heavy stream inlet, a second light stream outlet, and a second heavy stream outlet; and a nozzle reactor. In some embodiments, the first heavy stream outlet of the first hydrocyclone is in fluid communication with the first heavy stream inlet of the second hydrocyclone and the second heavy stream outlet is in fluid communication with the second material feed port of the nozzle reactor.

The above summarized methods and systems can advantageously provide a mechanism for separating hydrocarbon material to be upgraded without the use of large and expensive distillation towers. The use of, for example, hydrocyclones in place of distillation towers for various separation steps in the lead up to upgrading hydrocarbon material can reduce the cost of the overall operation and can allow for such operations to be carried out in locations where space is limited, such as on offshore platforms.

These and other aspects of the present system will be apparent after consideration of the Detailed Description and Figures herein. It is to be understood, however, that the scope of the invention shall be determined by the claims as issued and not by whether given subject matter addresses any or all issues noted in the Background or includes any features or aspects recited in this Summary.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1 is flow chart illustrating a hydrocarbon upgrading method according to various embodiments described herein;

FIG. 2 shows a cross-sectional view of some embodiments of a nozzle reactor suitable for use in various embodiments of the systems and methods described herein;

FIG. 3 shows a cross-sectional view of the top portion of the nozzle reactor shown in FIG. 2;

FIG. 4 shows a cross-sectional perspective view of the mixing chamber in the nozzle reactor shown in FIG. 2;

FIG. 5 shows a cross-sectional perspective view of the distributor from the nozzle reactor shown in FIG. 2;

FIG. 6 shows a cross-sectional view of some embodiments of a nozzle reactor suitable for use in various embodiments of the systems and methods described herein;

FIG. 7 shows a cross-sectional view of the top portion of the nozzle reactor shown in FIG. 7;

FIG. 8 shows a block diagram of a hydrocarbon upgrading system according to various embodiments described herein;

FIG. 9 shows a block diagram of a hydrocarbon upgrading system according to various embodiments described herein;

FIG. 10 is a cross-sectional view embodiments of a hydrocyclone suitable for use in various embodiments of the methods and systems described herein; and

FIG. 11 is a graph detailing cyclone residue capture efficiency as a function of pressure and temperature for implementations of the methods and systems described herein in upstream applications.

DETAILED DESCRIPTION

With reference to FIG. 1, some embodiments of a method for upgrading hydrocarbon include a step 1000 of providing a hydrocarbon material, a step 1100 of separating the hydrocarbon material in a cyclonic separation step, and a step 1200 of upgrading hydrocarbon separated in the cyclonic separation step. The method provides an alternative to the traditional use of distillation towers when separating certain hydrocarbon fractions from a hydrocarbon source for future upgrading. In so doing, the overall cost of the upgrading process can be reduced and the process can be carried out in locations where space is limited.

In step 1000, a hydrocarbon material is provided. In some embodiments, the hydrocarbon material is a material including hydrocarbon molecules in need of upgrading. While the hydrocarbon material can include non-hydrocarbon material, in some embodiments the majority of the hydrocarbon material will be hydrocarbon molecules. In some embodiments, the hydrocarbon material will include hydrocarbon molecules having a range of boiling point temperatures. The hydrocarbon molecules included in the hydrocarbon material can generally be classified as being either light hydrocarbon molecules or heavy hydrocarbon molecules, with the delineation between light hydrocarbon molecules and heavy hydrocarbon molecules being based on a selected boiling point temperature (i.e., light hydrocarbon molecules have a boiling point temperature below the selected boiling point temperature and heavy hydrocarbon molecules have a boiling point temperature above the selected boiling point temperature). Any boiling point temperature can be selected as the cut off between light and heavy hydrocarbon molecules. In some embodiments, the selected boiling point temperature is 850° F. or 1,050° F.

The hydrocarbon material can be obtained from any suitable source material, including from oil sands, tars sands, and other hydrocarbon deposit. In some embodiments, the hydrocarbon material is obtained from tar sands or oil sands. The tar sands or oil sands can be extracted from tar sands or oil sands deposits, and then subjected to any suitable separation processing in order to separate hydrocarbon material from water, sand, clay, and other solid materials typically found in extracted oil sands and tar sands.

In some embodiments, the hydrocarbon material comprises bitumen. The bitumen can be obtained from any bitumen source, including the oil sands and tar sands discussed above.

Bitumen typically includes hydrocarbon molecules having a wide range of boiling point temperatures, including a quantity of hydrocarbon molecules having a boiling temperature of greater than 1,050° F. and which are desirably separated from the other lighter hydrocarbon molecules and subjected to upgrading processing.

In some embodiments, the hydrocarbon material is hydrocarbon material that has previously undergone upgrading processing, such as upgrading through the use of a nozzle reactor. Hydrocarbon material obtained from upgrading processing can have a range of different hydrocarbon molecules, including light hydrocarbons formed from the upgrading processing, and heavy hydrocarbons that were not cracked or were insufficiently cracked during the upgrading processing. In embodiments where the hydrocarbon material was cracked in a nozzle reactor, the hydrocarbon material can also include cracking material, such as steam. The cracking material interacts with the hydrocarbon material in the nozzle reactor to result in hydrocarbon cracking, and can exit the nozzle reactor with the upgraded hydrocarbon material.

In some embodiments, the hydrocarbon material provided in step 1000 is pretreated prior to be being separated in a cyclonic separation. In some embodiments, the pretreatment involves the heating of the hydrocarbon material. The hydrocarbon material can be heated to any suitable temperature, such as to a temperature of greater than 350° F. It may be desirable to carry out this heating step in order to facilitate the separation of lighter hydrocarbons from the high boiling range hydrocarbons. The manner of heating the hydrocarbon material is not limited, and in some embodiments, a fire heater is used to heat the hydrocarbon material.

In step 1100, the hydrocarbon material is separated in a cyclonic separation step. The cyclonic separation step is generally carried out in order to separate light hydrocarbons from heavy hydrocarbons. It is generally desirable to separate the light hydrocarbons from the heavy hydrocarbons so that the heavy hydrocarbons can be upgraded in the relative absence of light hydrocarbons. The light hydrocarbons tend to already be in a commercially useful form and can be readily transported through pipelines, and therefore subjecting the light hydrocarbons to upgrading can be uneconomical. Additionally, the presence of light hydrocarbons during upgrading of heavy hydrocarbons can unfavorably affect the conversion of heavy hydrocarbons to lighter hydrocarbons.

Any cyclonic separation step suitable for separating hydrocarbons of varying boiling points can be used. In some embodiments, the cyclonic separation step is carried out using a hydrocyclone. Any type of hydrocyclone apparatus known to those of ordinary skill in the art and that is capable of separating the various components of a material injected therein can be used in step 1100. Typical hydrocyclones suitable for use in the above described method and system include hydrocyclone separators that utilize centrifugal forces to separate materials of different density, size, and/or shape. Hydrocyclones suitable for use in the methods described herein can include a stationary vessel having an upper cylindrical section narrowing to form a conical base. The hydrocarbon material is introduced into the hydrocyclone at a direction generally perpendicular to the axis of the hydrocyclone. This induces a spiral rotation on the material inside the hydrocyclone and enhances the radial acceleration on the heavier hydrocarbons within the material. The hydrocyclone also typically includes two outlets. The underflow outlet is situated at the bottom of the cyclone, and the overflow outlet is an axial tube rising to the vessel top (sometimes also called the vortex finder).

Separation of the hydrocarbon material in the hydrocyclone can generally begin by injecting the hydrocarbon into the hydrocyclone via a hydrocyclone injection passage. Once the hydrocarbon material is injected into the hydrocyclone, the heavier hydrocarbon molecules migrate quickly towards the cone wall, where the flow is directed downwards. Lighter hydrocarbon molecules (and, in some cases, cracking material) migrate more slowly and therefore may be captured in the upward spiral flow and exit from a vortex finder via the low pressure center.

Factors affecting the separation efficiency include fluid velocity, density, and viscosity, as well as the mass, size, and density of the hydrocarbon material components. The geometric configuration of the hydrocyclone can also play a role in separation efficiency. Parameters that can be varied to adjust separation efficiency include cyclone diameter, inlet width and height, overflow diameter, position of the vortex finder, height of the cylindrical chamber, total height of the hydrocyclone, and underflow diameter. Some or all of these parameters can be adjusted in order to effect a desired separation of the hydrocarbon material, such as a separation of hydrocarbons based on a selected boiling point temperature.

In some embodiments, the pressure and temperature conditions of the cyclones can be adjusted in improve performance of the methods and systems described herein. The cylones used in the methods and systems described herein can be used at both vacuum conditions and conditions above atmospheric pressure. In some embodiments, the selection of the pressure conditions depends on the context in which the cyclones are being used. In some embodiments, vacuum conditions for the cyclones are preferred when the methods and systems described herein are used in a refinery setup. In a specific example, the system of one or more hydrocyclones and a nozzle reactor can be used to replace cokers in traditional refinery settings. In this example, it is preferred that the hydrocyclones be operated at vacuum conditions, as results are achieved. In upstream applications, such as integrating the systems and methods described herein with bitumen extraction techniques (e.g., SAGD processing), operating the hydrocyclones at above atmospheric conditions can be preferred.

FIG. 11 provides a chart showing how the cyclone residue capture efficiency increases with increased pressure, while decreasing temperature can also improve efficiency. This chart supports the description above for operating the cyclones at above atmospheric pressure for upstream applications of the described methods and systems.

In some embodiments, two or more hydrocyclones can be used in series in order to separate the hydrocarbon material into three or more streams. In such a configuration, either the light stream or the heavy stream from the preceding hydrocyclone will be injected into a downstream hydrocyclone to further separate the material injected into the downstream hydrocyclone. Each hydrocyclone in the series of hydrocyclones can be tailored to effect a different separation. For example, a hydrocarbon material can be injected into a hydrocyclone designed to separate hydrocarbon molecules having a boiling point temperature less than 850° F. from hydrocarbon molecules having a boiling point temperature greater than 850° F., followed by injecting the hydrocarbon molecules having a boiling point temperature greater than 850° F. into a hydrocyclone designed to separate hydrocarbon molecules having a boiling point temperature greater than 1,050° F. from hydrocarbon molecules having a boiling point temperature less than 1,050° F. The use of multiple hydrocyclones in this manner can provide a more complete and efficient separation of the hydrocarbon material into individual streams.

After the separation of the hydrocarbon stream in the one or more hydrocylones, a stream of heavy hydrocarbon and a stream of light hydrocarbon (which, in some embodiments, includes cracking material) are obtained. In some embodiments, the stream of heavy hydrocarbon material will include predominantly hydrocarbon molecules having a boiling point temperature greater than 850° F. or 1,050° F., while the stream of light hydrocarbon will include predominantly hydrocarbon molecules having a boiling point temperature less than 850° F. or 1,050° F. As described in greater detail below, the heavy hydrocarbon material can be sent to a nozzle reactor for upgrading. The light hydrocarbon stream (which can include cracking material) can be sent to any separation unit known to those of ordinary skill in the art for separating water, off gas, and the like from the light hydrocarbon material. In some embodiments, this separation is carried out in a three phase separator.

In step 1200, the heavy hydrocarbon stream is upgraded in a nozzle reactor in order to crack the heavy hydrocarbon into lighter, more commercially useful hydrocarbon material. Any nozzle reactor suitable for use in upgrading hydrocarbon material can be used in step 1200. In some embodiments, the nozzle reactor used to carry out step 1200 is similar or identical to embodiments of the nozzle reactor described in U.S. Pat. No. 7,618,597; U.S. Pat. No. 7,927,565, U.S. Pat. No. 7,988,847; U.S. patent application Ser. No. 12/579,193; U.S. patent application Ser. No. 12/749,068; U.S. patent application Ser. No. 12/816,844; U.S. patent application Ser. No. 12/911,409; U.S. patent application Ser. No. 13/227,470, U.S. patent application Ser. No. 13/292,747; U.S. patent application Ser. No. 13/532,453; U.S. patent application Ser. No. 13/589,927; and/or U.S. patent application Ser. No. 13/593,045, each of which is hereby incorporated by reference in its entirety. The nozzle reactors described in these patents and patent applications generally receive a cracking material and accelerate it to a supersonic speed via a converging and diverging injection passage. Hydrocarbon material is injected into the nozzle reactor adjacent the location the cracking material exits the injection passage and at a direction transverse to the direction of the cracking material. The interaction between the cracking material and the hydrocarbon material results in the cracking of the hydrocarbon material into a lighter hydrocarbon material.

FIGS. 2 and 3 show cross-sectional views of one embodiment of a nozzle reactor 100 suitable for use in the methods described herein. The nozzle reactor 100 includes a head portion 102 coupled to a body portion 104. A main passage 106 extends through both the head portion 102 and the body portion 104. The head and body portions 102, 104 are coupled together so that the central axes of the main passage 106 in each portion 102, 104 are coaxial so that the main passage 106 extends straight through the nozzle reactor 100.

It should be noted that for purposes of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

The nozzle reactor 100 includes a feed passage 108 that is in fluid communication with the main passage 106. The feed passage 108 intersects the main passage 106 at a location between the portions 102, 104. The main passage 106 includes an entry opening 110 at the top of the head portion 102 and an exit opening 112 at the bottom of the body portion 104. The feed passage 108 also includes an entry opening 114 on the side of the body portion 104 and an exit opening 116 that is located where the feed passage 108 meets the main passage 106.

During operation, the nozzle reactor 100 includes a reacting fluid that flows through the main passage 106. The reacting fluid enters through the entry opening 110, travels the length of the main passage 106, and exits the nozzle reactor 100 out of the exit opening 112. A feed material flows through the feed passage 108. The feed material enters through the entry opening 114, travels through the feed passage 106, and exits into the main passage 108 at exit opening 116.

The main passage 106 is shaped to accelerate the reacting fluid. The main passage 106 may have any suitable geometry that is capable of doing this. As shown in FIGS. 2 and 3, the main passage 106 includes a first region having a convergent section 120 (also referred to herein as a contraction section), a throat 122, and a divergent section 124 (also referred to herein as an expansion section). The first region is in the head portion 102 of the nozzle reactor 100.

The convergent section 120 is where the main passage 106 narrows from a wide diameter to a smaller diameter, and the divergent section 124 is where the main passage 106 expands from a smaller diameter to a larger diameter. The throat 122 is the narrowest point of the main passage 106 between the convergent section 120 and the divergent section 124. When viewed from the side, the main passage 106 appears to be pinched in the middle, making a carefully balanced, asymmetric hourglass-like shape. This configuration is commonly referred to as a convergent-divergent nozzle or “con-di nozzle”.

The convergent section of the main passage 106 accelerates subsonic fluids since the mass flow rate is constant and the material must accelerate to pass through the smaller opening. The flow will reach sonic velocity or Mach 1 at the throat 122 provided that the pressure ratio is high enough. In this situation, the main passage 106 is said to be in a choked flow condition.

Increasing the pressure ratio further does not increase the Mach number at the throat 122 beyond unity. However, the flow downstream from the throat 122 is free to expand and can reach supersonic velocities. It should be noted that Mach 1 can be a very high speed for a hot fluid since the speed of sound varies as the square root of absolute temperature. Thus the speed reached at the throat 122 can be far higher than the speed of sound at sea level.

The divergent section 124 of the main passage 106 slows subsonic fluids, but accelerates sonic or supersonic fluids. A convergent-divergent geometry can therefore accelerate fluids in a choked flow condition to supersonic speeds. The convergent-divergent geometry can be used to accelerate the hot, pressurized reacting fluid to supersonic speeds, and upon expansion, to shape the exhaust flow so that the heat energy propelling the flow is maximally converted into kinetic energy.

The flow rate of the reacting fluid through the convergent-divergent nozzle is isentropic (fluid entropy is nearly constant). At subsonic flow the fluid is compressible so that sound, a small pressure wave, can propagate through it. At the throat 122, where the cross sectional area is a minimum, the fluid velocity locally becomes sonic (Mach number=1.0). As the cross sectional area increases the gas begins to expand and the gas flow increases to supersonic velocities where a sound wave cannot propagate backwards through the fluid as viewed in the frame of reference of the nozzle (Mach number >1.0).

The main passage 106 only reaches a choked flow condition at the throat 122 if the pressure and mass flow rate is sufficient to reach sonic speeds, otherwise supersonic flow is not achieved and the main passage will act as a venturi tube. In order to achieve supersonic flow, the entry pressure to the nozzle reactor 100 should be significantly above ambient pressure.

The pressure of the fluid at the exit of the divergent section 124 of the main passage 106 can be low, but should not be too low. The exit pressure can be significantly below ambient pressure since pressure cannot travel upstream through the supersonic flow. However, if the pressure is too far below ambient, then the flow will cease to be supersonic or the flow will separate within the divergent section 124 of the main passage 106 forming an unstable jet that “flops” around and damages the main passage 106. In one embodiment, the ambient pressure is no higher than approximately 2-3 times the pressure in the supersonic gas at the exit.

The supersonic reacting fluid collides and mixes with the feed material in the nozzle reactor 100 to produce the desired reaction. The high speeds involved and the resulting collision produces a significant amount of kinetic energy that helps facilitate the desired reaction. The reacting fluid and/or the feed material may also be pre-heated to provide additional thermal energy to react the materials.

The nozzle reactor 100 may be configured to accelerate the reacting fluid to at least approximately Mach 1, at least approximately Mach 1.5, or, desirably, at least approximately Mach 2. The nozzle reactor may also be configured to accelerate the reacting fluid to approximately Mach 1 to approximately Mach 7, approximately Mach 1.5 to approximately Mach 6, or, desirably, approximately Mach 2 to approximately Mach 5.

As shown in FIG. 3, the main passage 106 has a circular cross-section and opposing converging side walls 126, 128. The side walls 126, 128 curve inwardly toward the central axis of the main passage 106. The side walls 126, 128 form the convergent section 120 of the main passage 106 and accelerate the reacting fluid as described above.

The main passage 106 also includes opposing diverging side walls 130, 132. The side walls 130, 132 curve outwardly (when viewed in the direction of flow) away from the central axis of the main passage 106. The side walls 130, 132 form the divergent section 124 of the main passage 106 that allows the sonic fluid to expand and reach supersonic velocities.

The side walls 126, 128, 130, 132 of the main passage 106 provide uniform axial acceleration of the reacting fluid with minimal radial acceleration. The side walls 126, 128, 130, 132 may also have a smooth surface or finish with an absence of sharp edges that may disrupt the flow. The configuration of the side walls 126, 128, 130, 132 renders the main passage 106 substantially isentropic.

The feed passage 108 extends from the exterior of the body portion 104 to an annular chamber 134 formed by head and body portions 102, 104. The portions 102, 104 each have an opposing cavity so that when they are coupled together the cavities combine to form the annular chamber 134. A seal 136 is positioned along the outer circumference of the annular chamber 134 to prevent the feed material from leaking through the space between the head and body portions 102, 104.

It should be appreciated that the head and body portions 102, 104 may be coupled together in any suitable manner. Regardless of the method or devices used, the head and body portions 102, 104 should be coupled together in a way that prevents the feed material from leaking and withstands the forces generated in the interior. In one embodiment, the portions 102, 104 are coupled together using bolts that extend through holes in the outer flanges of the portions 102, 104.

The nozzle reactor 100 includes a distributor 140 positioned between the head and body portions 102, 104. The distributor 140 prevents the feed material from flowing directly from the opening 141 of the feed passage 108 to the main passage 106. Instead, the distributor 140 annularly and uniformly distributes the feed material into contact with the reacting fluid flowing in the main passage 106.

As shown in FIG. 5, the distributor 140 includes an outer circular wall 148 that extends between the head and body portions 102, 104 and forms the inner boundary of the annular chamber 134. A seal or gasket may be provided at the interface between the distributor 140 and the head and body portions 102, 104 to prevent feed material from leaking around the edges.

The distributor 140 includes a plurality of holes 144 that extend through the outer wall 148 and into an interior chamber 146. The holes 144 are evenly spaced around the outside of the distributor 140 to provide even flow into the interior chamber 146. The interior chamber 146 is where the main passage 106 and the feed passage 108 meet and the feed material comes into contact with the supersonic reacting fluid.

The distributor 140 is thus configured to inject the feed material at about a 90° angle to the axis of travel of the reacting fluid in the main passage 106 around the entire circumference of the reacting fluid. The feed material thus forms an annulus of flow that extends toward the main passage 106. The number and size of the holes 144 are selected to provide a pressure drop across the distributor 140 that ensures that the flow through each hole 144 is approximately the same. In one embodiment, the pressure drop across the distributor is at least approximately 2000 pascals, at least approximately 3000 pascals, or at least approximately 5000 pascals.

The distributor 140 includes a wear ring 150 positioned immediately adjacent to and downstream of the location where the feed passage 108 meets the main passage 106. The collision of the reacting fluid and the feed material causes a lot of wear in this area. The wear ring is a physically separate component that is capable of being periodically removed and replaced.

As shown in FIG. 5, the distributor 140 includes an annular recess 152 that is sized to receive and support the wear ring 150. The wear ring 150 is coupled to the distributor 140 to prevent it from moving during operation. The wear ring 150 may be coupled to the distributor in any suitable manner. For example, the wear ring 150 may be welded or bolted to the distributor 140. If the wear ring 150 is welded to the distributor 140, as shown in FIG. 4, the wear ring 150 can be removed by grinding the weld off. In some embodiments, the weld or bolt need not protrude upward into the interior chamber 146 to a significant degree.

The wear ring 150 can be removed by separating the head portion 102 from the body portion 104. With the head portion 102 removed, the distributor 140 and/or the wear ring 150 are readily accessible. The user can remove and/or replace the wear ring 150 or the entire distributor 140, if necessary.

As shown in FIGS. 2 and 3, the main passage 106 expands after passing through the wear ring 150. This can be referred to as expansion area 160 (also referred to herein as an expansion chamber). The expansion area 160 is formed largely by the distributor 140, but can also be formed by the body portion 104.

Following the expansion area 160, the main passage 106 includes a second region having a converging-diverging shape. The second region is in the body portion 104 of the nozzle reactor 100. In this region, the main passage includes a convergent section 170 (also referred to herein as a contraction section), a throat 172, and a divergent section 174 (also referred to herein as an expansion section). The converging-diverging shape of the second region differs from that of the first region in that it is much larger. In one embodiment, the throat 172 is at least 2-5 times as large as the throat 122.

The second region provides additional mixing and residence time to react the reacting fluid and the feed material. The main passage 106 is configured to allow a portion of the reaction mixture to flow backward from the exit opening 112 along the outer wall 176 to the expansion area 160. The backflow then mixes with the stream of material exiting the distributor 140. This mixing action also helps drive the reaction to completion.

The dimensions of the nozzle reactor 100 can vary based on the amount of material that is fed through it. For example, at a flow rate of approximately 590 kg/hr, the distributor 140 can include sixteen holes 144 that are 3 mm in diameter. The dimensions of the various components of the nozzle reactor shown in FIGS. 2 and 3 are not limited, and may generally be adjusted based on the amount of feed flow rate if desired. Table 1 provides exemplary dimensions for the various components of the nozzle reactor 100 based on a hydrocarbon feed input measured in barrels per day (BPD).

TABLE 1 Exemplary nozzle reactor specifications Feed Input (BPD) Nozzle Reactor Component (mm) 5,000 10,000 20,000 Main passage, first region, 254 359 508 entry opening diameter Main passage, first region, 75 106 150 throat diameter Main passage, first region, 101 143 202 exit opening diameter Main passage, first region, length 1129 1290 1612 Wear ring internal diameter 414 585 828 Main passage, second region, 308 436 616 entry opening diameter Main passage, second region, 475 672 950 throat diameter Main passage, second region, 949 1336 1898 exit opening diameter Nozzle reactor, body potion, 1300 1830 2600 outside diameter Nozzle reactor, overall length 7000 8000 10000

It should be appreciated that the nozzle reactor 100 can be configured in a variety of ways that are different than the specific design shown in the Figures. For example, the location of the openings 110, 112, 114, 116 may be placed in any of a number of different locations. Also, the nozzle reactor 100 may be made as an integral unit instead of comprising two or more portions 102, 104. Numerous other changes may be made to the nozzle reactor 100.

Turning to FIGS. 6 and 7, another embodiment of a nozzle reactor 200 is shown. This embodiment is similar in many ways to the nozzle reactor 100. Similar components are designated using the same reference number used to illustrate the nozzle reactor 100. The previous discussion of these components applies equally to the similar or same components includes as part of the nozzle reactor 200.

The nozzle reactor 200 differs a few ways from the nozzle reactor 100. The nozzle reactor 200 includes a distributor 240 that is formed as an integral part of the body portion 204. However, the wear ring 150 is still a physically separate component that can be removed and replaced. Also, the wear ring 150 depicted in FIG. 7 is coupled to the distributor 240 using bolts instead of by welding. It should be noted that the bolts are recessed in the top surface of the wear ring 150 to prevent them from interfering with the flow of the feed material.

In FIGS. 6 and 7, the head portion 102 and the body portion 104 are coupled together with a clamp 280. The seal, which can be metal or plastic, resembles a “T” shaped cross-section. The leg 282 of the “T” forms a rib that is held by the opposing faces of the head and body portions 102, 104. The two arms or lips 284 form seals that create an area of sealing surface with the inner surfaces 276 of the portions 102, 104. Internal pressure works to reinforce the seal.

The clamp 280 fits over outer flanges 286 of the head and body portions 102, 104. As the portions 102, 104 are drawn together by the clamp, the seal lips deflect against the inner surfaces 276 of the portions 102, 104. This deflection elastically loads the lips 284 against the inner surfaces 276 forming a self-energized seal. In one embodiment, the clamp is made by Grayloc Products, located in Houston, Tex.

With reference to FIG. 8, a hydrocarbon upgrading system 400 suitable for use in carrying out embodiments of the methods described above can include a hydrocyclone 410 and a nozzle reactor 420. The hydrocyclone 410 separates a hydrocarbon material 401 into a light hydrocarbon stream 411 and a heavy hydrocarbon stream 412, and the nozzle reactor 420 receives the heavy hydrocarbon stream 412 and upgrades the hydrocarbon molecules in the heavy hydrocarbon stream 412 through the interaction with cracking material 421.

The hydrocyclone 410 provided in the system 400 can be similar or identical to the hydrocyclone described in greater detail above in step 1100. Generally speaking, the hydrocyclone 410 uses centrifugal forces and density differences to separate the hydrocarbon material into two streams. The light hydrocarbon stream 411 reports to the overflow and generally includes hydrocarbon molecules having a boiling point temperature below a selected temperature. The heavy hydrocarbon stream 412 reports to the underflow and generally includes hydrocarbon molecules having a boiling point temperature above a selected temperature and which tend to require upgrading before the material can be considered commercially useful and/or transportable through a pipeline.

The nozzle reactor 420 provided in the system 400 can be similar or identical to the nozzle reactor described in greater detail above in step 1200. The nozzle reactors described in these patents and patent applications generally provide an injection passage for cracking material capable of accelerating the cracking to a supersonic speed and an injection passage for the hydrocarbon material that is aligned transverse to the injection passage for the cracking material. The two materials are simultaneously injected into a reaction chamber of the nozzle reactor, at which point the interaction between the two materials results in the cracking of the hydrocarbon material. Thus, as shown in FIG. 8, the heavy hydrocarbon stream 412 is transported from the underflow outlet of the hydrocyclone 410 and injected into the feed material injection port of the nozzle reactor 420 at a direction transverse to the direction the cracking material stream 421 is injected into the nozzle reactor, and an upgraded hydrocarbon material product 422 exits the nozzle reactor 420.

Although not shown in FIG. 8, all of the hydrocarbon stream 412 leaving the hydrocyclone 410 need not be injected into the nozzle reactor 420. In some embodiments, a portion of the hydrocarbon stream 412 is purged while the remainder of the hydrocarbon stream is sent to the nozzle reactor 420 as illustrated in FIG. 8. Such a purge stream may be useful when the flow rate of the hydrocarbon stream 412 produced by the hydrocyclone 410 is greater than what can be handled by the nozzle reactor 420 and also to prevent the build up of unwanted contaminants in the system.

Also not shown in FIG. 8 is an optional recycle stream that can be provided between the nozzle reactor 420 and the hydrocyclone 410. In some embodiments, such a recycle stream (which can be taken from, e.g., hydrocarbon material product 422) provides a manner for the product of the nozzle reactor 420 to be sent back to the hydrocylone 410 for further separation. A benefit of using the recycle stream is that any heavy hydrocarbon material that passes through the nozzle reactor 420 uncracked can be separated from the cracked product of the nozzle reactor 420 and re-injected into the nozzle reactor 420 so that another attempt at cracking and upgrading the heavy hydrocarbon material is performed. In some embodiments, the recycled nozzle reactor product is combined with fresh hydrocarbon material (i.e., hydrocarbon material that has not yet undergone separation in the hydrocyclone 410 or upgrading in the nozzle reactor 420) and the combined stream is injected into the hydrocyclone 410.

With reference to FIG. 9, a hydrocarbon upgrading system 500 is provided that includes a first hydrocyclone 510, a second hydrocyclone 520, and a nozzle reactor 530. The system 500 is thus similar to the system 400, with the exception of including a second hydrocyclone 520 intermediate the first hydrocyclone 510 and the nozzle reactor 530. The second hydrocyclone 520 is provided for separating one of the streams leaving the first hydrocyclone 510. In some embodiments, a light hydrocarbon stream 512 and a heavy hydrocarbon stream 511 are produced by the first hydrocyclone 510, with the first heavy hydrocarbon stream 511 being injected into the second hydrocyclone 520 in order to separate the heavy hydrocarbon stream 511 into a second heavy hydrocarbon stream 521 and a second light hydrocarbon stream 522. The second heavy hydrocarbon stream 521 can then be transported to the nozzle reactor 530 and injected into the material feed injection port for upgrading. The use of a system 500 with a first hydrocyclone 510 and a second hydrocyclone 520 can provide for a more efficient and complete separation of the initial hydrocarbon material, so that the stream injected into the nozzle reactor 530 includes predominantly hydrocarbon molecules in need of upgrading. While FIG. 9 illustrates the use of two hydrocyclones, more than two hydrocyclones can also be used in the system 500.

One advantage of the systems 400 and 500 described above is that the system have a relatively small footprint (as compared to, e.g., a system using distillation towers for separation) and can therefore be used in operations where space is limited. Once such operation is on an offshore platform. In some embodiments, the systems described herein are located on an offshore platform. In such embodiments, material recovered from deposits located under the floor of a body of water can be separated using the one or more hydrocyclones. The one or more hydrocyclone ultimately provide a heavy hydrocarbon material that can be injected into a nozzle reactor located on the offshore platform in order to upgrade the material. The upgraded material produced by the nozzle reactor can then be more easily and economically transported back to shore (such as, e.g., through the use of underwater pipelines) then would be possible if the recovered hydrocarbon material were not upgraded on the offshore platform.

Similar purge streams and recycle streams as described above with reference to FIG. 4 can also be used in the system illustrated in FIG. 5. Purge streams can be provided after each hydrocylone, and recycle streams can be directed from the nozzle reactor to any combination of the hydrocylones included in the system.

Further details of an offshore upgrading system using a nozzle reactor are described in co-pending U.S. Provisional Patent Application No. 61/525,515, hereby incorporated by reference in its entirety. The features of the offshore upgrading system described in U.S. Provisional Patent Application No. 61/525,515 can be used in conjunction with the hydrocyclone and nozzle reactor features described herein.

EXAMPLES

FIG. 10 is an example of a hydrocyclone that can be used to separate heavy hydrocarbons in a nozzle reactor application. The hydrocyclone shown can be designed for the separation of a hydrocarbon stream with the following characteristics:

CYCLONE INLET Vapour Liquid Stream Name Cyc Inlet Phase Phase Vapour/Phase Fraction 0.982 0.982 0.018 Temperature [F.] 698.5 698.5 698.5 Pressure [psia] 29.7 29.7 29.7 Molar Flow [lbmole/hr] 20625.2 20259.8 365.4 Mass Flow [lb/hr] 799974 574176 225798 Std Ideal Liq Vol Flow [barrel/day] 56363 42055 14308

While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.

A presently preferred embodiment of the present invention and many of its improvements have been described with a degree of particularity. It should be understood that this description has been made by way of example, and that the invention is defined by the scope of the following claims. 

We claim:
 1. A hydrocarbon upgrading method comprising: providing a hydrocarbon material having light hydrocarbon molecules and heavy hydrocarbon molecules; separating the light hydrocarbon molecules of the hydrocarbon material from the heavy hydrocarbon molecules of the hydrocarbon molecules using a cyclonic separation; and upgrading the heavy hydrocarbon molecules in a nozzle reactor.
 2. The hydrocarbon upgrading method as claimed in claim 1, wherein the hydrocarbon material comprises bitumen.
 3. The hydrocarbon upgrading method as claimed in claim 1, wherein the light hydrocarbon molecules have a boiling point temperature less than 1,050° F. and the heavy hydrocarbon molecules have a boiling point temperature greater than 1,050° F.
 4. The hydrocarbon upgrading method as claimed in claim 1, wherein upgrading the heavy hydrocarbon molecules comprises: injecting a stream of cracking material through a converging then diverging passage of a cracking material injector into a reaction chamber; and injecting the heavy hydrocarbon molecules into the reaction chamber adjacent to the cracking material injector and transverse to the stream of cracking material entering the reaction chamber from the cracking material injector.
 5. The hydrocarbon upgrading method as claimed in claim 4 wherein the heavy hydrocarbon molecule injecting step includes injecting the heavy hydrocarbon molecules into the reaction chamber annularly around the stream of cracking material.
 6. A hydrocarbon upgrading method comprising: providing a hydrocarbon material; separating the hydrocarbon material into a first heavy stream and a first light stream in a first hydrocyclone; separating the first heavy stream into a second light stream and a second heavy stream in a second hydrocyclone; and upgrading the second heavy stream in a nozzle reactor.
 7. The hydrocarbon upgrading method as claimed in claim 6, wherein the hydrocarbon material comprises bitumen.
 8. The hydrocarbon upgrading method as claimed in claim 6, wherein the first heavy stream comprises predominantly hydrocarbon molecules having a boiling point temperature greater than 850° F. and the second heavy stream comprises predominantly hydrocarbon molecules having a boiling point temperature greater than 1,050° F.
 9. The hydrocarbon upgrading method as claimed in claim 6, wherein upgrading the second heavy stream comprises: injecting a stream of cracking material through a converging then diverging passage of a cracking material injector into a reaction chamber; and injecting the second heavy stream into the reaction chamber adjacent to the cracking material injector and transverse to the stream of cracking material entering the reaction chamber from the cracking material injector.
 10. The hydrocarbon upgrading method as claimed in claim 9 wherein the second heavy stream injecting step includes injecting the second heavy stream into the reaction chamber annularly around the stream of cracking material.
 11. A hydrocarbon upgrading system comprising: a hydrocyclone having a light stream outlet and a heavy stream outlet; and a nozzle reactor comprising: a reactor body having a reactor body passage with an injection end and an ejection end; a first material injector having a first material injection passage and being mounted in the nozzle reactor in material injecting communication with the injection end of the reactor body passage, the first material injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end in material injecting communication with the combustion chamber, and (c) a material ejection end in material injecting communication with the reactor body passage; and a second material feed port penetrating the reactor body and being (a) adjacent to the material ejection end of the first material injection passage and (b) transverse to a first material injection passage axis extending from the material injection end to the material ejection end in the first material injection passage in the first material injector; wherein the heavy stream outlet of the hydrocyclone is in fluid communication with the second material feed port of the nozzle reactor.
 12. The hydrocarbon upgrading system as claimed in claim 11, wherein the hydrocarbon upgrading system is located on an offshore platform.
 13. A hydrocarbon upgrading system comprising: a first hydrocyclone having a first light stream outlet and a first heavy stream outlet; a second hydrocyclone having a first heavy stream inlet, a second light stream outlet, and a second heavy stream outlet; and a nozzle reactor comprising: a reactor body having a reactor body passage with an injection end and an ejection end; a first material injector having a first material injection passage and being mounted in the nozzle reactor in material injecting communication with the injection end of the reactor body passage, the first material injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end in material injecting communication with the combustion chamber, and (c) a material ejection end in material injecting communication with the reactor body passage; and a second material feed port penetrating the reactor body and being (a) adjacent to the material ejection end of the first material injection passage and (b) transverse to a first material injection passage axis extending from the material injection end to the material ejection end in the first material injection passage in the first material injector; wherein the first heavy stream outlet of the first hydrocyclone is in fluid communication with the first heavy stream inlet of the second hydrocyclone and the second heavy stream outlet is in fluid communication with the second material feed port of the nozzle reactor.
 14. The hydrocarbon upgrading system as claimed in claim 13, wherein the hydrocarbon upgrading system is located on an offshore platform. 